Welding system with breath-based control

Abstract

A new welding system is provided that makes use of breath of the operator to control one or more operating parameters of the power source or welding machine (or “welder”). The welding system may be configured for arc welding, and the welding machine or welder may include a constant voltage power source with varying current (or vice versa). In such an embodiment, the welding system includes a breath-based controller with a mouthpiece through which the operator can breathe or blow in air. The breath-based controller processes the user's breath to determine user input, and this operator input is communicated to the welder or welding machine (via wired or wireless communication links) to control arc intensity (i.e., current for a constant voltage welding machine) or arc length (i.e., voltage for a constant current welding machine). An operator uses the breath-based controller to remotely control the welding machine with high precision.

We claim: 
     
         1 . A controller adapted for breath-based control of welding, comprising:
 an output interface transmitting control signals to a welding machine to define a value of at least one operating parameter of the welding machine during operations of welding machine;   a mouthpiece assembly adapted to receive breath of an operator of the welding machine;   a sensor sensing a pressure based on the breath in the mouthpiece assembly; and   a processor processing the pressure sensed by the sensor and, in response, generating the control signals.   
     
     
         2 . The controller of  claim 1 , wherein the at least one operating parameter is welding intensity generated by the welding machine. 
     
     
         3 . The controller of  claim 2 , wherein the welding machine is adapted for arc welding and wherein the at least one operating parameter sets a current or voltage level for the welding machine. 
     
     
         4 . The controller of  claim 1 , wherein the processor runs a mapping module to map a magnitude of the pressure sensed by the sensor to a value of the at least one operating parameter falling within a predefined range for the welding machine. 
     
     
         5 . The controller of  claim 4 , wherein the sensor is adapted to have sensitivity range falling in the range of 0 to 1.5 pounds per square inch (PSI) and wherein the sensitivity range is mapped in a linearized manner or with a non-linear fit to the predefined range for the at least one operating parameter. 
     
     
         6 . The controller of  claim 1 , wherein the control signals are generated by the processor based on the pressure sensed by the sensor to cause the welding machine to provide a stepped output or a pulsed output. 
     
     
         7 . The controller of  claim 1 , wherein the mouthpiece assembly comprises an upper segment with an inlet member and a hollow body defining a chamber for receiving the breath that passes through a channel in the inlet member, wherein the mouthpiece assembly further comprises a lower segment with a hollow body defining a chamber for receiving a volume of fluid, wherein the mouthpiece assembly further comprises a membrane formed of a resilient material separating the chamber of the upper segment from the chamber of the lower segment, and wherein the lower segment includes an outlet member providing a channel to fluidically couple the chamber of the lower segment with the sensor, whereby the sensor senses the pressure as a change in a pressure of the fluid based on elastic deformation of the membrane by the breath. 
     
     
         8 . A welding system adapted for breath-based control, comprising:
 a welder with an energy source; and   a breath-based controller communicatively linked in a wired or wireless manner to the welding machine, the breath-based controller including:
 an output interface transmitting a control signal to the welder to adjust an operating parameter of the energy source during operations of the welding system; 
 a mouthpiece assembly with an inlet member for receiving breath of an operator of the welding system and with a channel providing a tubular passage to an inner chamber; 
 a sensor sensing pressure of the breath in the inner chamber and outputting a pressure signal; and 
 a digital or analog processor generating the control signal based on the pressure signal. 
   
     
     
         9 . The system of  claim 8 , wherein the welder is an arc welder and wherein the operating parameter is a current level or a voltage level for the energy source, whereby a welding intensity of the welder is controlled by the breath-based controller. 
     
     
         10 . The system of  claim 8 , wherein the processor is digital and executes code to map the pressure sensed by the sensor to a value of the operating parameter of the energy source. 
     
     
         11 . The system of  claim 10 , wherein the sensor is adapted to have sensitivity range falling in the range of 0 to 1.5 pounds per square inch (PSI) and wherein the sensitivity range is mapped in a linearized manner or with a non-linear fit to a predefined range for the operating parameter. 
     
     
         12 . The system of  claim 8 , wherein the control signal is generated by the processor based on the pressure sensed by the sensor to cause the energy source to provide a stepped output or a pulsed output. 
     
     
         13 . The system of  claim 8 , wherein the mouthpiece assembly comprises an upper segment with the inlet member and a hollow body defining the chamber for receiving the breath that passes through a channel in the inlet member, wherein the mouthpiece assembly further comprises a lower segment with a hollow body defining a chamber for receiving a volume of fluid, wherein the mouthpiece assembly further comprises a membrane adapted for elastic deformation separating the chamber of the upper segment from the chamber of the lower segment, and wherein the lower segment includes an outlet member providing a channel to fluidically couple the chamber of the lower segment with the sensor, whereby the sensor senses the pressure as a change in a pressure of the fluid. 
     
     
         14 . A controller adapted for breath-based control of welding, comprising:
 an output interface transmitting control signals in a wired or wireless manner to a welding machine to define a value of an operating parameter of an energy source of the welding machine;   an inlet member for receiving breath of an operator of the welding system and with a channel providing a tubular passage to an inner chamber;   a sensor sensing pressure of the breath in the inner chamber and outputting a pressure signal; and   a digital or analog processor generating the control signal based on the pressure signal.   
     
     
         15 . The system of  claim 14 , wherein the mouthpiece assembly comprises an upper segment with the inlet member and a hollow body defining the chamber for receiving the breath that passes through a channel in the inlet member, wherein the mouthpiece assembly further comprises a lower segment with a hollow body defining a chamber for receiving a volume of fluid, wherein the mouthpiece assembly further comprises a membrane adapted for elastic deformation separating the chamber of the upper segment from the chamber of the lower segment, and wherein the lower segment includes an outlet member providing a channel to fluidically couple the chamber of the lower segment with the sensor, whereby the sensor senses the pressure as a change in a pressure of the fluid. 
     
     
         16 . The system of  claim 14 , wherein the processor is digital and operates to map the pressure sensed by the sensor to a value of the operating parameter of the energy source. 
     
     
         17 . The system of  claim 16 , wherein the sensor is adapted to have sensitivity range falling in the range of 0 to 1.5 pounds per square inch (PSI) and 
     
     
         18 . The system of  claim 17 , wherein the sensitivity range is mapped in a linearized manner or with a non-linear fit to a predefined range for the operating parameter. 
     
     
         19 . The system of  claim 14 , wherein the welder is an arc welder and wherein the operating parameter is a current level or a voltage level for the energy source, whereby a welding intensity of the welder is controlled by the breath-based controller. 
     
     
         20 . The system of  claim 14 , wherein the control signal is generated by the processor based on the pressure sensed by the sensor to cause the energy source to provide a stepped output or a pulsed output.